Apparatus for assembling cartons and like containers

ABSTRACT

This specification discloses a carton assembling apparatus comprising blank folding die units having blank end folding members, blank side fold and side or end flap folding members positioned to fold the blank in a predetermined sequence, and a blank pusher which bears on the base of the blank to force same into the die unit, said blank pusher having a blank holding mechanism including blank engaging pads which are brought into contact with the blank when in the folded condition to hold same in place while the adhesive for the blank sets.

United States Patent 1191 Corderoy 1111 3,800,681 14 1 Apr. 2,1974

1' APPARATUS FOR ASSEMBLING CARTONS AND LIKE CONTAINERS [75] Inventor: Henry Morgan Corderoy,

Sandringham, Australia [73] Assigncc: AC1 Operations Pty. Limited,

Victoria, Australia 221 Filed: Sept. 11, 1972 [21] App]. No.: 287,886

[30] Foreign Application Priority Data Oct/28, 1971 Australia 6825/71 Dec. 20, 1971 Australia....; 7470/71 July 20,- 1972 Australia 44794/72 [52] U.S. Cl. 93/51 R, 93/31, 93/52, 93/59 .R [511' Int. Cl ..B3lb1/4 4 [58] Field of Search... 93/51 R, 52, 49 R, 53 R,

93/59 R, 59 PL, 84 R, 47, 48, 41, 41.1,31

[56] References Cited UNITED STATES PATENTS 3,301,144 1/1967 Reeves... 93/49 R X 1,163,863 12/1915 Schlegcl 93/51 R 3,690,222 9/1972 Schroeder 93/52 2,829,569 4/1958 Aquilla.; 93/51 R 2,176,122 10/1939 Chapman.... 93/52 3,178,168 4/1965 Aherncthy.. 93/59 R UX 3,504,838 4/1970 (airatti 93/59 R X FOREIGN PATENTS OR APPLICATIONS Germany 9.3/51 R Primary Examiner Roy Lake Assistant Examiner-Jamcs F. Coan Attorney, Agent, or FirmLarson, Taylor and Hinds [57] v ABSTRACT This specification discloses a carton assembling apparatus'comprising blank folding die unitshaving blank end, folding members, blank side fold and side or end flap folding members positioned to fold the blank in a predetennined sequence, and a blank pusher which bears on the base of the blank to force same into the die unit, said blank pusher having a blank holding mechanism including blank engaging pads which are brought into contact with the blank when in the folded condition to hold same in place while the adhesive for the blank sets.

11 Claims, 14 Drawing Figures I PATENTEIJAPR 2-1974 SHEET 5 [IF v7 PATENLTEBAPR 2-1914 38063 681 sum 6 or 7 APPARATUS FOR ASSEMBLING CARTONS AND LIKE CONTAINERS This invention relates to apparatus for assembling cartons, such as corrugated fibreboard boxes, from scored or folded cardboard fibreboard or like blanks.

The object of this invention is to provide an apparatus which assists in the assembly of cartons.

In one aspect the invention provides an apparatus for I the assemblyof cartons and the like from blanks comprising a support, one or more die units comprising a plurality of blank folding members which are formed to performJfolding of the blank when the blank is forced into-the die unit either manually or by means ofa blank pusher associated with the apparatus.

In another aspect, the invention provides an apparatus for the assembly of cartons and the like from blanks comprising. a support for a die unit comprising a plurality of blank folding members which are formed to perform folding of the blank when the blank is forced into the'die unit, said folding members including blank end folding members, blank side folding members and side or end flap folding members which are positioned to fold. the blank in a predetermined sequence, said side and end folding members being arranged to define at least part of the outline of the base of the carton or the like.

The apparatus may furtherinclude a blank pushing device mounted on the support in overlying relationhip. to the die, l mit, and Comprising a pusher plate for engaging the base of the carton blank, and means for moving said plate into said die unit.

In addition the blank pushing means may have a blank holding'mechanism fixed thereto and comprising blank engaging means mounted on laterally movable members, and means for holding said members in an extended condition in which said engaging means apply pressure to the blank when assembled in the die unit in regions of the blank required to be adhesively connected.

FIG. 1 is a perspective view from above of a carton blank folding die unit and blank pusher embodying the invention;

FIG. 2 is a partly fragmentary view similar to FIG. 1 showing a carton blank folded within the die unit;

FIGS. 3a and 3b are end elevations of part of the blank pusher for the die unit showing the blank holder thereof in the expanded and retracted positions respectivel F IGS. 4a and 4b are a fragmentary side elevation and a cross-sectional end elevation of the mechanism which controls the lowering and raising of the blank pusher;

FIG. 5 is a perspective view from above of an alternative form of blank folding die unit;

FIG. 6 is a perspective view of another blank folding apparatus embodying the invention;

FIG. 7 shows the manner in which the adhesive applicator is used;

FIGS. 8 to 10 show the manner in which the lid blank folding die unit of the apparatus folds a carton lid blank to the assembled condition, and I FIGS. 11 and 12 show the manner in which the box blank folding die unit folds a box blank.

The blank folding die unit and pusher assembly shown in FIG. 1 is one of four assemblies, which are identical except for the spacing of their blank folding members to fold boxes and lids respectively, mounted on a square frame 1 secured to a central post 2, which may be rotatable about a vertical axis to allow the respective lid and box die units to be presented to one or more operators in succession.

The die unit D comprises two sets of three blank end folding members 3 mounted in spaced relation on supporting frames 4 fixed to frame 1, and two sets of two blank side folding members 5 secured in spaced relation to the frame 1 and to the frames 4 respectively. Each folding member comprises a plate formed with a horizontal top portion 6, an intermediate inclined portion or camming surface 7 and a vertical portion 8. The outermost end folding members 3 have side flap folding members 9 in the form of arched metal strips welded to their flat portions 6. g The side folding members 3 near the free ends of the frames 4 are mounted for adjustment longitudinally of the frames 4 by bolts 10 passing through slotted holes, by means of which the members 5 at this end are secured to the frames 4. The frames 4 are also adjustably mounted on the frame 1 by means of bolts and clamp plates and both degrees of adjustability allow the die unit D to be used for different carton sizes.

Positioned above the die unit D is a blank pusher P comprising a pusher plate 11, having a shape generally corresponding to the shape of the base of the carton lid and box, fixedto a vertically movable pusher rod 12, pivotally secured at its upper end to an actuating lever 13. The lever 13 is pivotally supported (FIG. 4) be tween spaced radial arms 14 fixed to the post 2 and braced by plates 15 fixed to the post 2.-The pivotal support of lever 13 is such as to ensure vertical movement of the pusher rod 12 and comprises a transverse pin 16 near the inner end of the lever engaging a slot 17 bev tween the arms 14 and plates 15, and links 19 pivoted to the arms 13 at 20 and to bearing blocks 21 secured to the arms 14 through lateral pins 22 extending from the links 19. The pusher assembly P is counterbalanced by means of tension springs 23 connected at one end to the radial arms 14 and at their other ends to links 24 which are fixed to rotate with pins 22 and thus with links 19. The downward movement of the pusher P is limited by an adjustable U'bolt (FIG. 2).

The pusher rod 12 also supports a blank holding mechanism (FIG. 3) comprising support plates 25 fixed to the rod 12 and holding pivot pins for legs 26 having pairs of blank engaging pads 27 at their free ends. The legs 26 are adapted to be held apart by cam-bearing arms 28 pivoted to the rod 12 and having an operating lever 29. Movement of the arms 28 in the opening direction is restricted by a stop S. On release of the arms 28, the legs 26 fall to the retracted position (FIG. 3b) under their own weight.

In use, the plates 3 and 5 of die units D are adjusted to suit the lids and boxes to be folded and a lid or box blank B is positioned on top of the relevant die unit D with its side flaps resting on the members 9 and the edges of the innermost side of the blank located against a locating plate 30. The ends then have their inner faces, at the regions contacted by the side flaps, coated with adhesive. The operator pulls the lever 13 down so that the pusher plate 11 bears on the base of the blank B and on further downward movement of the lever 13 the side flaps are folded perpendicularly to the sides by the members 9. The ends are then partially folded by the plates 3 whereupon the sides are fully folded by the plates 5. On further downward movement, the ends are fully folded to bring the adhesive coating into engagement with the side flaps. The operating lever 29 is then pushed across to expand the legs 26 so that the pads 27 engage the side flaps to hold them in pressure engagement with the ends of the blank.

When the adhesive is sufficiently set, the legs 26 are released and the pusher P withdrawn, leaving the box or lid B in the die unit D, whereupon a fresh blank may be positioned on the die unit D. When the fresh blank is forced into the die unit as described above it pushes the completed box or lid out of the die unit D.

It will be appreciated that the operation of the blank pusher P may be mechanised, say in timed relation to the manual or automatic feeding of blanks. For example, the pushers may be operated by cam means actuated on rotation of the apparatus or in any other suitable way. Alternatively, the pusher P may be replaced bya manually held member. Furthermore, the various folding members may be replaced by equivalent constructions adapted to perform the folding in the same or a different sequence. The sequence may be altered by changing the positions of the folding members relative to the initial position of the flat blank B. For example, the members 3 may be shifted upwardly to cause the ends to be completely folded before the ends are folded, the side flaps being folded either before or after the sides but before complete folding of the ends.

In the alternative form shown in FIG. 5, the die unit D is adjustably secured to cross bars C fixed to a vertical support post V which also supports a pusher P (not shown) the same as in the previous embodiment. The die unit D is functionally identical to the previous die unit only the end foldingmembers 3 and one of the side folding members are formed from single sheet metal plates. The construction and operation of this alternative is otherwise obvious from the drawing, in which like reference numerals refer to like parts of the previous embodiment.

Referring now to FIGS. 6 to 12, the blank folding apparatus shown is adapted to assist in the manual folding of carton lids and boxes.

The apparatus comprises a hollow cubic structure 100 mounted on a stand 101 for rotational movement about a vertical axis. Mounted on the four vertical faces of-the cubic structure 100 are two pairs of die units 102 and 103 adapted to assist in the assembly of the box B, and the lid C respectively of a carton. The stand 101 is provided with means 104 for applying adhesive to the pre-cut'blanks.

The adhesive applying means 104 includes an adhesive trough 105 having axle supports 106 at its ends. The supports 106 have two vertically spaced axles secured thereto, the'lower of which rotatably supports two spaced adhesive applying rollers 107, which dip into the adhesive in trough 105, and the upper of which 4 rotatably supports two similarly positioned guide rollers 108.

The die unit 103 for the assembly of lids C comprises two sets of four formed rods 109 secured to and extending from the face of structure 100, each set being secured at their outermost ends to a formed plate 110.

Each rod 109 has a first portion 111 perpendicular to the face, a second portion 112 parallel to the face and a third portion 113 parallel to the first portion 111. Each set of rods 109 has an outer pair of rods of identical configuration and a central pair of rods of identical configuration, the outer pair of rods having their second portions 112 closer to the face than the second portions 112 of the central pair of rods. The arcuate portions of the rods connecting the second and third portions define blank camming surfaces. The formed plates 110 are identical and are of flanged channelsection configuration. The configuration of the rods and plates will be clear from the following description of the uses of the apparatus in assembling a lid C.

The first step (FIG. 7) of the procedure is to apply the adhesive to one side of the lid by inserting the blank, printed face up, between the rollers 107 and 108 and then to the other side by rotating the blank through 180 and repeating the procedure. The blank is then slid under the rods and pulled outwardly towards the operator (FIG. 8). This movement causes the camming surfaces of the outer pairs of rods to engage and fold the flaps of the ends of the lid perpendicularly to the ends. On further outward movement, the lid ends are engaged by the comers between the flanges and sides of the plates 110 and are folded perpendicularly to the base of the lid (FIG. 9). Further outward movement causes the central pairs of rods to fold the sides against the flaps of the ends causing the adhesive thereon to contact these flaps to produce a lid C (FIG. 10).

The cubic structure 100 of the apparatus is then rotated through to locate one of the die units 102 above the adhesive means 104. Each die unit 102 includes a set of four shaped rods 114 arranged at the comers of a rectangle about the size of the base of the box, a set of two shaped rods 115 positioned centrally of the long sides of the rectangle and a set of four shaped rods 116 positioned one at or near each corner of the rectangle. Each of the rods in the various sets have a portion perpendicular to the face of the structure and a portion which is bent at an obtuse angle to the first portion in a direction outwardly of the centre of the die unit. The lowermost of the rods has a foot 117 thereon adapted to initially support and align the blank with the other rods. The positions of the bends in the sets of rods will be clear from the following description of assembly of a box using the apparatus.

The box blank is coated with adhesive as described in relation to the lid. The blank is then positioned with one side resting on the foot 117 and the blank pushed towards the face so that the rods 114 cause the ends to be folded perpendicular to the base (FIG. 1 1). Next the sides are folded by the rods 115 (FIG. 12) whereupon the end flaps are folded over the sides so that the flaps contact the adhesive coated areas of the sides.

It will be appreciated that the apparatus described reduces significantly the manual assembly time even though the apparatus is simple in construction. While the folding members are formed from rods the embodiment, any other suitable member with the required configuration may be used. For cartons having differv 1 5 ently shaped blanks, the folding members are shaped to perform the required folding functions. The adhesive applying means may be replaced by other suitable means. For example, the rods 109 may be tubular and incorporate adhesive sprays for coating the required areas of the sides of lid. Similarly the rods 115 could support spray arms for coating the required areas of the which are formed to perform folding of the blank when the base of the .blank is forced into the die unit, said folding members including blank end folding members, blank side folding members and side or end flap folding members which are positioned to fold the blank in a predetermined sequence, said side and end. folding members being arranged to define at least part of the outline of the base of the carton or the like, a blank pushing device mounted on the support in overlying relationship to the die unit and comprising a pusher plate for engaging the base of the carton blank, and means for moving said plate into said die unit, said plate moving means comprising a pusher rod connected perpendicularly to said plate and pivotally connected to an actuating lever which is in turn pivotally connected to supporting means, the last mentioned pivotal connection including a sliding pivotal connection between the lever and the supporting means and a link pivoted to the arm and to the supporting means between the operating end of the lever and said sliding pivotal connection, the link pivot and the sliding pivot being spaced to ensure substantially linear movement of said pusher rod. g

2. An apparatus according to claim 1, wherein each blank folding member includes a blank camming surface exte'nding at an acute angle to a line parallel to the direction of movement of the blank into said die unit.

3. An apparatus according to claim 2, wherein each 1 blank folding member comprises a plate having a downwardly and inwardly inclined portion defining said camming surface and connected to a vertical portion, the vertical portions of the plurality of members being fixed in a pattern defining at least a part of the outline of the base of the carton.

4. An apparatus according to claim 3, wherein the plates constituting the blank side or end folding members have end or side flap folding members secured thereto above the camming surfaces of said plates for folding said flaps generally perpendicularly to the end or side of the blank prior to the other folding operations.

5. An apparatus for the assembly of cartons and the like from blanks comprising a plurality of blank folding members which are formed to perform folding of the blank when the base of the blank is forced into the die unit, said folding members including blank end folding members, blank side folding members and side or end flap folding members which are positioned to fold the blank in a predetermined sequence, said side and end folding members being arranged to define at least part of the outline of the base of the carton or the like, a blank pushing device mounted on the support in overlying relationship to the die unit and comprising a pusher plate for engaging the base of the carton blank, and means for moving said plate into said die unit, a blank holding mechanism fixed to said pushing device and comprising blank engaging means mounted on laterally movable members, means for holding said members in an extended condition in which said engaging means apply pressure to the blank when assembled in the die unit in regions of the blank required to be adhesively connected, and wherein said laterally movable members comprise angular legs pivoted to the pushing device at one end and supporting blank engaging pads at the other end, and cam means for holding said legs in an extended condition.

6. An apparatus for the assembly of cartons and the like from blanks comprising means supporting a die unit comprising a plurality of blank folding members which are formed to perform folding of the blank when the base of the blank is forced into the die unit, said folding members including blank end folding members, blank side folding members and side or end flap folding members which are positioned to fold the blank in a predetermined sequence, said side and end folding members being arranged to define at least part of the outline of the base of the carton or the like, and wherein said die unit comprises two spaced'sets of at least three rods connected at one end to the supporting means and at their other ends to a formed plate capable of receiving part of the base of a carton blank when assembled, said rods comprising a first portion perpendicular to the supporting means, a second portion perpendicular to the first portion and a third portion perpendicular to the second portion and parallel to the first portion, the length of the first portion of two of said rods in each set being less than that of the corresponding portion of the other rod, the rods in each set being spaced to perform folding operations on a blank forced from said first portions towards the formed plates. 1

7. An apparatus according to claim 6, wherein said apparatus includes a further die unit comprising a set of four shaped rods arranged near the corners of a rectangle about the same size as the base of the carton, a set of two shaped rods positioned centrally of two corresponding sides of the rectangle and another set of four shaped rods arranged near the corners of the rectangle, each rod having a first portion perpendicular to the support means and a second portion at an obtuse angle of said first portion, the first portions of the first mentioned set of four rods being longer than the corresponding portions of the second set, these corresponding portions being shorter than the first portions of the set of two rods.

8. An apparatus according to claim 1, wherein said sliding pivotal connection is between a transverse pin near the inner end of said lever and slots in said supporting means.

nected thereto, said cam-bearing arms being positioned between said angular legs.

10. An apparatus according to claim 9, wherein said 11. An apparatus according to claim 6, wherein said pushing device supports a stop positioned to prevent angular legs are pivoted at their upper ends and hang movement of said cam-bearing arms past the fully exin a retracted position under their own weight. tended position of said laterally movable members. 

1. An apparatus for the assembly of cartons and the like from blanks comprising means supporting a die unit comprising a plurality of blank folding members which are formed To perform folding of the blank when the base of the blank is forced into the die unit, said folding members including blank end folding members, blank side folding members and side or end flap folding members which are positioned to fold the blank in a predetermined sequence, said side and end folding members being arranged to define at least part of the outline of the base of the carton or the like, a blank pushing device mounted on the support in overlying relationship to the die unit and comprising a pusher plate for engaging the base of the carton blank, and means for moving said plate into said die unit, said plate moving means comprising a pusher rod connected perpendicularly to said plate and pivotally connected to an actuating lever which is in turn pivotally connected to supporting means, the last mentioned pivotal connection including a sliding pivotal connection between the lever and the supporting means and a link pivoted to the arm and to the supporting means between the operating end of the lever and said sliding pivotal connection, the link pivot and the sliding pivot being spaced to ensure substantially linear movement of said pusher rod.
 2. An apparatus according to claim 1, wherein each blank folding member includes a blank camming surface extending at an acute angle to a line parallel to the direction of movement of the blank into said die unit.
 3. An apparatus according to claim 2, wherein each blank folding member comprises a plate having a downwardly and inwardly inclined portion defining said camming surface and connected to a vertical portion, the vertical portions of the plurality of members being fixed in a pattern defining at least a part of the outline of the base of the carton.
 4. An apparatus according to claim 3, wherein the plates constituting the blank side or end folding members have end or side flap folding members secured thereto above the camming surfaces of said plates for folding said flaps generally perpendicularly to the end or side of the blank prior to the other folding operations.
 5. An apparatus for the assembly of cartons and the like from blanks comprising a plurality of blank folding members which are formed to perform folding of the blank when the base of the blank is forced into the die unit, said folding members including blank end folding members, blank side folding members and side or end flap folding members which are positioned to fold the blank in a predetermined sequence, said side and end folding members being arranged to define at least part of the outline of the base of the carton or the like, a blank pushing device mounted on the support in overlying relationship to the die unit and comprising a pusher plate for engaging the base of the carton blank, and means for moving said plate into said die unit, a blank holding mechanism fixed to said pushing device and comprising blank engaging means mounted on laterally movable members, means for holding said members in an extended condition in which said engaging means apply pressure to the blank when assembled in the die unit in regions of the blank required to be adhesively connected, and wherein said laterally movable members comprise angular legs pivoted to the pushing device at one end and supporting blank engaging pads at the other end, and cam means for holding said legs in an extended condition.
 6. An apparatus for the assembly of cartons and the like from blanks comprising means supporting a die unit comprising a plurality of blank folding members which are formed to perform folding of the blank when the base of the blank is forced into the die unit, said folding members including blank end folding members, blank side folding members and side or end flap folding members which are positioned to fold the blank in a predetermined sequence, said side and end folding members being arranged to define at least part of the outline of the base of the carton or the like, and wherein said die unit comprises two spaced sets of at least three rods connected at one end to the supporting means and at their other ends to a formed plate capable of receiving part of the base of a carton blank when assembled, said rods comprising a first portion perpendicular to the supporting means, a second portion perpendicular to the first portion and a third portion perpendicular to the second portion and parallel to the first portion, the length of the first portion of two of said rods in each set being less than that of the corresponding portion of the other rod, the rods in each set being spaced to perform folding operations on a blank forced from said first portions towards the formed plates.
 7. An apparatus according to claim 6, wherein said apparatus includes a further die unit comprising a set of four shaped rods arranged near the corners of a rectangle about the same size as the base of the carton, a set of two shaped rods positioned centrally of two corresponding sides of the rectangle and another set of four shaped rods arranged near the corners of the rectangle, each rod having a first portion perpendicular to the support means and a second portion at an obtuse angle of said first portion, the first portions of the first mentioned set of four rods being longer than the corresponding portions of the second set, these corresponding portions being shorter than the first portions of the set of two rods.
 8. An apparatus according to claim 1, wherein said sliding pivotal connection is between a transverse pin near the inner end of said lever and slots in said supporting means.
 9. An apparatus according to claim 6, wherein said cam means comprises cam-bearing arms pivoted to the pushing device and having an operating lever connected thereto, said cam-bearing arms being positioned between said angular legs.
 10. An apparatus according to claim 9, wherein said pushing device supports a stop positioned to prevent movement of said cam-bearing arms past the fully extended position of said laterally movable members.
 11. An apparatus according to claim 6, wherein said angular legs are pivoted at their upper ends and hang in a retracted position under their own weight. 